Chart Title
Mass of Components
16175
VISHNU INSTITUTE OF TECHNOLOGY
TECHNICAL & PERFORMANCE SPECIFICATIONS MAX.SPEED60kmph
MAX. ACCELERATION5.735 m/s2
% OF GRADABILITY46
STOPPING DISTANCE7.06m
MATERIALTUBINGSAISI 4130NORMALISED STEEL
WALL THICKNESS0.76
COCKPIT DIMENSIONS38X 32.23
LENGTH92
HEIGHT42
WIDTH64
TRACK WIDTH58
WHEEL BASE68
GROUND CLEARENCE7.47
NO. OF WELDS45
WELD LENGTH1.91(for one joint )
TUBE(OD)1
KERB WEIGHT300Kg
Diameter of TyreType of tyre
24ATV 24X 8
Measurements in mm also in bracketsWhat is wells length how is
it calculated?Laden weight 300 or unladen?
ROLL CAGE DESIGN
Material AISI 4130 NORMALISED STEEL
STEEL DENSITY7.85gm/cc
YIELD STRENGTH460MPa
TENSILE STRENGTH560MPa
POISSONS RATIO0.285
Reduce the table size or add animation to show other views
ROLL CAGE ANALYSIS
Engine and Seat AnalysisRear Analysis
Front Analysis
Side Analysis
Show stresses and maximum stress value and the fos for each
crash. Don't show this wobbly diagram a color map would do. Skye
mesh size
ParametersFrontSuspensionRearSuspension
Wire diameter8.6 mm8.6 mm
Inner coil diameter51.6 mm51.6 mm
Outer coil diameter60.2 mm60.2mm
Total number of turns3635
Free length of strut423.15 mm403.23mm
Pitch of suspension spring12.09mm11.85mm
Eye-to-eye length of strut (unloaded)50.56mm44.42mm
Max. dynamic spring travel101.12 mm88.9 mm
Design of spring Center of gravity heightGround clearanceRoll
centerMotion ratios
10.07'7.47At ground0.5
Camber(Negative)CasterKPIScrub radiusToe inToe out
0.540000
SUSPENSION GEOMETRYParametersFRONT SUSPENSIONREAR SUSPENSION
DAMPING RATIO0.50.5
STIFFNESS 25.46 N/mm48.42N/mm
RIDE FREQUENCY1.135Hz1.23 Hz
WHEEL RATE4.83 N/mm8.415 N/mm
DESIGN OF DAMPERLINKAGE DESIGNSUSPENSION
What is eyev to length and how is it lesser than travel?Your
spring design is wrong.The maruti kingpin will have a non zero
inclination. Hence the scrub will also not be zero.Wasn't the ride
frequency 1.25 and 1.5
Componentsselection
Type of brakeHydraulic- 4 disc brakes to 4 wheels
Master cylinderMaruti 800 Bosch
Brake circuitX-split
Caliper and DiscMaruti Suzuki 800
CalculationsValues
Brake Pedal force784 N
Force on Caliper1747.2 N
Braking Torque188.6 N-m
Stopping distance7.06m at 40 kmph
Stopping time1.27 s (from 40 to 0 kmph)
Deceleration8.73 m/s2
Weight Transfer557 N
Specifications Values
Disc diameter Outer/inner220 mm/160mm
Caliper piston diameter38.1 mm
Master cylinder diameter25 mm
Pedal ratio4:1
BRAKE SYSTEM
Brake Disc of Maruti 800
Stopping from not atEnsure calculations
STEERING SYSTEM
COMPONENTMeasurement
Wheel base68
Wheel track58
Inner steering angle40
Outer steering angle26.12
Length of tie-rod39.90
Steering ratio12:1
Turning circle radius2.79 m
Rack travel4.25(lock to lock)
Pinion turn1.5 rev (lock to lock)
Component measurement
Ackermanns %85.54
IBJ centre distance14
OBJ centre distance36.359
Steering No power assist
Steering wheel diameter12.59
Steering torque64 N-m
MODIFIED KNUCKLE DESIGNWhat's this king pin. Measurements in
mmHow was steering torque calculated.
POWER TRAIN
SpecificationsValues
Power10 HP
Max torque23.8 N-m@2500 rpm
Max speed16.66 m/s
Tyre size24
Transmission efficiency0.8
GEARRATIOSMAX . SPEED (m/s)MAX . TORQUE (N-m)TRACTIVE FORCE
(N)
ROLLING RESISTANCE (N)Max.ACCELERATION (m/S2)
1ST31.48:13.61749.2242140.645.75.735
2ND18.70:16.11445.061271.646.973.0407
3RD11.40:110271.32775.248.82.077
4TH7.66:115.5182.308499.851.411.339
Reverse55.08:11.941266.843745.4445.0110.03
Gear Box Assembly
Briggs &Stratton Engine
How was rolling resistance calculated. Remove it.And efficiency
mention gear box name
S.NO.COMPONENTMASS(KG)COST(INR)SPRUNG/UNSPRUNG
1CHASSIS77268/msprung
2ENGINE26.7650,000sprung
3GEAR BOX36-4015,000sprung
4GEAR LEVER0.05-0.08300sprung
5CLUTCH1.721250sprung
6SUSPENSION SYSTEM KIT23.665000sprung
7BRAKE PADS0.15-0.25600unsprung
8BRAKE CALIPER1.8-2.21500unsprung
9BRAKE FLUID(ml)355 509unsprung
10MASTER CYLINDER0.20-0.25250unsprung
11FRONT LEFT TYRE(24")16.3620,000unsprung
12FRONT RIGHT TYRE(24")16.3620,000unsprung
13REAR LEFT TYRE(24")16.3620,000unsprung
14REAR RIGHT TYRE(24")16.3620,000unsprung
15STEERING KIT56,000sprung
Bill of Materials
Delete spring/ unsprung. Add safety equipment make all wheels
one.
GANTT CHART
Event is Feb.Where is time for manufacturing
NoCOMPONENT FAILURE MODE FAILURE CAUSE FAILURE EFFECTPREVENTIVE
ACTIONS
1FrameStructural failureDue to excess load.Overall Damage to
roll cage. Choose material with high factor of safety(FOS).
2EngineEngine damageUnavailability clean air and proper
fuelengine failure and risk to drivers lifeadditional safety to
driver
3TransmissionMechanical failureFatigue/ cyclic
loadinginoperableSuitable Transmission system
4.
Steering systemBreakage, mechanical failure.Excess load applied
by driver.Steering failure; Safety of driver.Verification of
desired specification and testing
5.KnucklesBreakage failureFailure due to bending, crushing
stressDamage to suspension system .Choose material with high
FOS.
6.Braking SystemMechanical failureNot sufficient braking
forceDamage to vehicle in undesired circumstancesChoose material
with high FOS and careful testing should be done
7.Tyres, rimsMechanical failuredamage by foreign debrisInability
to operate vehicleVerification of proper specification and
testing
8.Driver seatStructural failure affecting safetyExcess load
leading to bearing stressEndangers drivers safetyProper fitting
should be done
9.Electrical componentsElectrical failureWater damage/electrical
failuredrivers safety from electrical contacts.Proper insulation
should be provided.
DFMEA
Please go through the last 2 ccolumns they make no sense and
seems made up.I will call and talk about it.
1.Grinding Machine
2.Power Hack Saw
3.Arc Welding Machine
5.Drilling Machine
6.Bending Machine
7.Lathe MachineWorkshop Facilities
4.CNC Machine
8.Universal testing machineTEAM STRATEGY -1.CHASSIS
DESIGN2.TRANSMISSION3.SUSPENSION4.BRAKES5.STEERING6.SAFETY &
ERGONOMICS7.ELECTRIAL CABLES
Sub teams instead of strategy
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